US9085835B2 - Kind of microfiber artificial leather and its manufacturing methods - Google Patents
Kind of microfiber artificial leather and its manufacturing methods Download PDFInfo
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- US9085835B2 US9085835B2 US13/203,665 US201113203665A US9085835B2 US 9085835 B2 US9085835 B2 US 9085835B2 US 201113203665 A US201113203665 A US 201113203665A US 9085835 B2 US9085835 B2 US 9085835B2
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- microfiber
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- warp
- polyurethane
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- 229920001410 Microfiber Polymers 0.000 title claims abstract description 68
- 239000003658 microfiber Substances 0.000 title claims abstract description 68
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 27
- 239000002649 leather substitute Substances 0.000 title claims abstract description 23
- 239000004744 fabric Substances 0.000 claims abstract description 41
- 229920000728 polyester Polymers 0.000 claims abstract description 22
- 229920005749 polyurethane resin Polymers 0.000 claims abstract description 15
- 238000000034 method Methods 0.000 claims abstract description 11
- 238000004043 dyeing Methods 0.000 claims abstract description 10
- 239000003513 alkali Substances 0.000 claims abstract description 9
- 238000007596 consolidation process Methods 0.000 claims abstract description 9
- 238000009941 weaving Methods 0.000 claims abstract description 6
- 239000007788 liquid Substances 0.000 claims description 24
- 239000010410 layer Substances 0.000 claims description 21
- ZMXDDKWLCZADIW-UHFFFAOYSA-N N,N-Dimethylformamide Chemical compound CN(C)C=O ZMXDDKWLCZADIW-UHFFFAOYSA-N 0.000 claims description 18
- 229920002635 polyurethane Polymers 0.000 claims description 18
- 239000004814 polyurethane Substances 0.000 claims description 18
- 239000000835 fiber Substances 0.000 claims description 12
- 230000003699 hair surface Effects 0.000 claims description 9
- 125000000129 anionic group Chemical group 0.000 claims description 7
- 239000003945 anionic surfactant Substances 0.000 claims description 7
- 230000001112 coagulating effect Effects 0.000 claims description 7
- 238000005516 engineering process Methods 0.000 claims description 7
- 239000002736 nonionic surfactant Substances 0.000 claims description 7
- 239000004745 nonwoven fabric Substances 0.000 claims description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 5
- 238000005304 joining Methods 0.000 claims description 4
- 239000012982 microporous membrane Substances 0.000 claims description 4
- 239000002356 single layer Substances 0.000 claims description 4
- 238000009987 spinning Methods 0.000 claims description 4
- 239000000178 monomer Substances 0.000 claims description 3
- -1 polytrimethylene terephthalate Polymers 0.000 claims description 3
- 229920002215 polytrimethylene terephthalate Polymers 0.000 claims description 3
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical group N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 claims description 2
- 229920002292 Nylon 6 Polymers 0.000 claims description 2
- 229920002302 Nylon 6,6 Polymers 0.000 claims description 2
- 230000000844 anti-bacterial effect Effects 0.000 claims description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 2
- 239000003063 flame retardant Substances 0.000 claims description 2
- 150000002500 ions Chemical class 0.000 claims description 2
- 229910052760 oxygen Inorganic materials 0.000 claims description 2
- 239000001301 oxygen Substances 0.000 claims description 2
- 239000011248 coating agent Substances 0.000 claims 2
- 238000000576 coating method Methods 0.000 claims 2
- 238000001035 drying Methods 0.000 claims 2
- 238000005406 washing Methods 0.000 claims 2
- 239000010985 leather Substances 0.000 abstract description 11
- 239000000463 material Substances 0.000 abstract description 3
- 230000001054 cortical effect Effects 0.000 abstract description 2
- 230000035699 permeability Effects 0.000 abstract description 2
- 239000000243 solution Substances 0.000 description 25
- YXFVVABEGXRONW-UHFFFAOYSA-N Toluene Chemical compound CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 description 6
- 239000002904 solvent Substances 0.000 description 3
- 239000004698 Polyethylene Substances 0.000 description 2
- 238000001467 acupuncture Methods 0.000 description 2
- 238000005452 bending Methods 0.000 description 2
- 230000009172 bursting Effects 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 239000000975 dye Substances 0.000 description 2
- 229920002521 macromolecule Polymers 0.000 description 2
- 229920001778 nylon Polymers 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- 238000012805 post-processing Methods 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 239000004677 Nylon Substances 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 208000030695 Sparse hair Diseases 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 239000012670 alkaline solution Substances 0.000 description 1
- 238000009960 carding Methods 0.000 description 1
- 230000015271 coagulation Effects 0.000 description 1
- 238000005345 coagulation Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 239000000806 elastomer Substances 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 239000002861 polymer material Substances 0.000 description 1
- 239000004753 textile Substances 0.000 description 1
- 231100000331 toxic Toxicity 0.000 description 1
- 230000002588 toxic effect Effects 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
Images
Classifications
-
- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D27/00—Woven pile fabrics
- D03D27/02—Woven pile fabrics wherein the pile is formed by warp or weft
- D03D27/06—Warp pile fabrics
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
- D06N3/14—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyurethanes
-
- D03D15/0061—
-
- D03D15/12—
-
- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
- D03D15/30—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the fibres or filaments
- D03D15/33—Ultrafine fibres, e.g. microfibres or nanofibres
-
- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
- D03D15/50—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads
- D03D15/513—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads heat-resistant or fireproof
-
- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D25/00—Woven fabrics not otherwise provided for
- D03D25/005—Three-dimensional woven fabrics
-
- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D27/00—Woven pile fabrics
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
- D06C13/00—Shearing, clipping or cropping surfaces of textile fabrics; Pile cutting; Trimming seamed edges
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
- D06N3/0004—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using ultra-fine two-component fibres, e.g. island/sea, or ultra-fine one component fibres (< 1 denier)
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
- D06N3/0006—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using woven fabrics
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
- D06N3/004—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using flocked webs or pile fabrics upon which a resin is applied; Teasing, raising web before resin application
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/007—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by mechanical or physical treatments
- D06N3/0072—Slicing; Manufacturing two webs at one time
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/007—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by mechanical or physical treatments
- D06N3/0075—Napping, teasing, raising or abrading of the resin coating
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2205/00—Condition, form or state of the materials
- D06N2205/24—Coagulated materials
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2211/00—Specially adapted uses
- D06N2211/12—Decorative or sun protection articles
- D06N2211/28—Artificial leather
Definitions
- This Invention relates to a kind of microfiber artificial leather and its manufacturing methods, more precisely, a kind of suede made taking ultrafine polyester as the major raw material, applying a special three-dimensional weaving process, using a special macromolecule polymer elastomer and adopting the wet leather manufacturing process, as well as corresponding manufacturing methods. It is a kind of textile and leather technology.
- the microfiber artificial leather produced abroad and at home mostly takes the sea-island superfine fiber as raw materials, experiences the opening, carding and netting process, accepts repeated consolidation on a acupuncture (or spunlace) machine to form a fabric, then has the sea part dissolved (or extracted) by polyurethane padding, coagulation and lye (or solvent) treatment, and finally accepts sanding, dyeing and finishing to make into finished products.
- the sea-island superfine fiber can be divided into volatile sea-island superfine fiber (volatile island microfiber) and fixed sea-island microfiber (fixed island microfiber).
- the island in volatile sea-island microfiber is not controllable, featuring non-continuity on the vertical axis, and can be made into microfiber featuring irregular thickness and length through solvent treatment; however, the fixed sea-island microfiber is continuous on the vertical axis, and a kind of symmetrical microfiber featuring a fixed number of islands, as well as consistent fiber and uniform length.
- the number of islands in fixed sea-island microfiber generally includes such specifications as 16 islands, 24 islands, 37 islands and 64 islands, with 37 islands in common use.
- nylon microfiber artificial leather featuring volatile island its volatile island microfiber is usually blended with polyamide and polyethylene or other soluble macromolecule polymer materials at a certain percentage based on the threading process, after the artificial leather fabric is fabricated, and then toluene is used to dissolve polyethylene for fiber opening followed by post-processing.
- the products based on this process have the fiber monofilament size up to 0.0001 dtex (for fine ones) and 0.1 dtex above (for thick ones).
- the larger discreteness of size may have certain effect on post-processing and product quality; and, in the process of production, the toxic solvent toluene is easy to evaporate, which has great influence on operators' health and environment.
- the characteristics of nylon fiber itself indicates that related products feature poor uniformity, low color fastness, poor abrasion resistance, no dense hair, low density and other defects, so that there should be certain limitations to its applications.
- Non-woven fabric is used as artificial leather fabric, and acupuncture (or spunlace) is adopted to have the fibers tangled together, but this entanglement has its instability, (and some manufacturers add a layer of woven fabric between non-woven fabrics to increase the stability of the product).
- acupuncture or spunlace
- the fiber is relatively easy to fall off from the product, that is, it features poor wear resistance. This process can not form enough three-dimensional fibers with sparse hair on the surface so that the products feel rough and can not meet requirements for use in some areas.
- this Invention provides a manufacturing method for microfiber artificial leather, including the steps as follows:
- Microfiber (such as a microfiber dyed before spinning) is select as pile warp, with the filament or yarn (such as a yarn dyed before spinning) taken as ground warp and ground weft.
- the pile warp adopts V-shaped or W-shaped consolidation, uses the double warp-pile weaving technology to weave into double-layer pile fabric on pile weavers, and adopts pile cutters to cut the pile warp thread joining the two layers of the ground fabric so that the double-layer pile fabric could be halved into single-layer pile fabric respectively with ground warp, ground weft and V-shaped or W-shaped pile warp, featuring a three-dimensional structure;
- the microporous membrane pile fabric with polyurethane contained is applied with alkali treatment, so that the pile warp could fully be dispersed into single fibers to form microfibers, and then fully washed in water to remove alkali liquid, as well as alkali-soluble monomers and oligomers;
- the described microfiber shall be polyester microfiber, PTT microfiber, PA6 or PA66 microfiber, and the yarn is highly strengthened filament or other filament;
- the microfiber is sea-island microfiber or split microfiber
- the multi-filament size of microfiber is 82.5-333 dtex
- the single filament size of microfiber is 0.55 dtex or below;
- the multi-filament size of yarn is 82.5-222 dtex
- the polyester microfiber can adopt flame-retardant polyester microfiber, anti-static polyester microfiber, antibacterial polyester microfiber or polyester microfiber with the function of negative ions of oxygen emission;
- the polyurethane resin finishing liquid described in Step (2) is a kind of solution prepared by polyurethane, DMF and anionic, and non-ionic surfactant;
- the polyurethane resin in polyurethane finishing solution has its concentration of 5%-30%, and the weight ratio of anionic and nonionic surfactants is 0-5%;
- the polyurethane resin has its concentration of 10%-20%, and the weight ratio of anionic and nonionic surfactants is 1-3%;
- the weight ratio between the polyurethane finishing liquid and pile fabric in Step (2) is 80%-400%;
- the weight ratio between the polyurethane finishing liquid and pile fabric in Step (2) is 100%-200%
- the coagulating liquid in Step (2) has the concentration of 10-30%;
- the alkali treatment in Step (3) has its temperature of 95-120 degrees, with the time of 10-30 minutes;
- the ground warp and ground weft in Step (1) can adopt producer-colored yarn
- the pile warp in Step (1) can adopt producer-colored microfiber
- Step (1) also includes another step to coat a layer of sea-island superfine polyester non-woven fabric on the back of the hair surface;
- Step (4) also includes another step to coat a layer of water-soluble polyurethane.
- Another technical solution of this Invention is to obtain polyester microfiber artificial leather based on the above-mentioned manufacturing methods
- artificial leather adopts yarn as ground warp and ground weft.
- the pile warp adopts V-shaped or W-shaped consolidation, uses the double warp-pile weaving technology to weave into double-layer pile fabric on pile weavers, and adopts pile cutters to cut the pile warp thread joining two layers of ground fabric so that the double-layer pile fabric could be halved into single-layer pile fabric respectively with ground warp, ground weft and V-shaped or W-shaped pile warp, featuring a three-dimensional structure;
- Another preferred solution of this Invention is to coat a layer of sea-island superfine polyester non-woven fabric on the back of the hair surface.
- Another preferred solution of this Invention is to coat a layer of water-soluble polyurethane on the back of the hair surface.
- microfiber artificial leather as garment leather, shoe leather, automotive interior materials or furniture leather.
- the artificial leather of this Invention features fine and smooth hair surface, high density, strong cortical feeling, good wear resistance, dimensional stability, good moisture permeability, good color fastness and excellent mechanical properties, able to be used as garment leather, shoe upper leather, car interior materials, furniture leather and so on.
- FIG. 1 shows the flow chart of the method mentioned in this Invention
- FIG. 2 shows the structure profile of pile warp V-shaped consolidation in this Invention
- FIG. 3 shows the structure profile of pile warp V-shaped consolidation in this Invention
- FIG. 4 shows the structure profile of pile warp W-shaped consolidation in this Invention
- FIG. 5 shows the structure profile of double-layered pile fabric in this Invention
- FIG. 6 shows the structure profile of single-layered pile fabric in this Invention
- the pile warp (1) adopts V-shaped (as shown in FIG. 2 or FIG. 3 ) or W-shaped (as shown in FIG. 4 ) consolidation, uses the double warp-pile weaving technology to weave into double-layer pile fabric (as shown in FIG.
- the coagulating liquid is a kind of solution prepared by DMF with the weight ratio of 10%-30% (preferably 15%-25%) and water.
- the sanding may have great impact on the plush feeling of the artificial leather hair surface
- this Invention adopts the sandpaper (220-600 meshes) surfaces of different types based on test to carry out several times of sanding treatment (first heavier, and then lighter) and obtain suedette artificial leather featuring standing hair and fine silky feeling.
- Dyeing steps Select high-quality dispersed dyes, such as those dispersed dyes featuring good wash fastness and excellent light fastness, make use of overflow dyeing machine for dyeing, strictly control the dyeing process conditions (130° C., 60 minutes), and strengthen after-dyeing wash to ensure uniform product color, pure shade and good color fastness.
- Example 2 Test the artificial leather microfiber obtained in Example 1 respectively from the gram weight, thickness, TABER wear resistance, flooding fade, bending at room temperature, bursting strength, tensile strength, elongation, tear strength, friction fade, peel strength and wet-type test, with the results as follows:
- Test Test Test Item Unit Results Test Item Unit Results Test Item Unit Results Gram weight g/m 2 390 Tensile A-oriented Kg/cm 16 Thickness mm 1.0 strength B-oriented Kg/cm 14 Breadth M 1.4 Elongation A-oriented % 85 TABER wear Cycles No damage after B-oriented % 120 resistance 100,000 times Flooding fade AATCC 4.0 Tear A-oriented Kg 4.7 Bending at Cycles No crack after strength B-oriented kg 4.2 room temperature 100,000 times Bursting Kg/cm 2 20 Friction Dry-type ATCC 4.5 strength fade Peel strength Kg/cm 3.4 Wet-type AATCC 4.0
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- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Nanotechnology (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Dispersion Chemistry (AREA)
- Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)
- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
- Woven Fabrics (AREA)
- Laminated Bodies (AREA)
Abstract
This Invention relates to a kind of microfiber artificial leather and its manufacturing methods, namely, adopting double-pile weaving process, taking highly-strengthened filament (or other filament) as ground warp and ground weft, using sea-island polyester microfiber or other microfiber as pile warp, adopting the V-shaped or W-shaped consolidation to weave into three-dimensional fabric, and then accepting padding of polyurethane resins, alkali treatment, sanding, dyeing and finishing. The artificial leather related in this Invention features delicate surface piles, high density, strong cortical feeling, good wear resistance, dimensional stability, good moisture permeability, good color fastness, and excellent mechanical properties, so it can be used as garment leather, shoe upper leather, car interior materials, furniture leather and so on.
Description
This Invention relates to a kind of microfiber artificial leather and its manufacturing methods, more precisely, a kind of suede made taking ultrafine polyester as the major raw material, applying a special three-dimensional weaving process, using a special macromolecule polymer elastomer and adopting the wet leather manufacturing process, as well as corresponding manufacturing methods. It is a kind of textile and leather technology.
Currently, the microfiber artificial leather produced abroad and at home mostly takes the sea-island superfine fiber as raw materials, experiences the opening, carding and netting process, accepts repeated consolidation on a acupuncture (or spunlace) machine to form a fabric, then has the sea part dissolved (or extracted) by polyurethane padding, coagulation and lye (or solvent) treatment, and finally accepts sanding, dyeing and finishing to make into finished products.
According to different production technologies, the sea-island superfine fiber can be divided into volatile sea-island superfine fiber (volatile island microfiber) and fixed sea-island microfiber (fixed island microfiber). The island in volatile sea-island microfiber is not controllable, featuring non-continuity on the vertical axis, and can be made into microfiber featuring irregular thickness and length through solvent treatment; however, the fixed sea-island microfiber is continuous on the vertical axis, and a kind of symmetrical microfiber featuring a fixed number of islands, as well as consistent fiber and uniform length. The number of islands in fixed sea-island microfiber generally includes such specifications as 16 islands, 24 islands, 37 islands and 64 islands, with 37 islands in common use.
For the nylon microfiber artificial leather featuring volatile island, its volatile island microfiber is usually blended with polyamide and polyethylene or other soluble macromolecule polymer materials at a certain percentage based on the threading process, after the artificial leather fabric is fabricated, and then toluene is used to dissolve polyethylene for fiber opening followed by post-processing. The products based on this process have the fiber monofilament size up to 0.0001 dtex (for fine ones) and 0.1 dtex above (for thick ones). The larger discreteness of size may have certain effect on post-processing and product quality; and, in the process of production, the toxic solvent toluene is easy to evaporate, which has great influence on operators' health and environment. Moreover, the characteristics of nylon fiber itself indicates that related products feature poor uniformity, low color fastness, poor abrasion resistance, no dense hair, low density and other defects, so that there should be certain limitations to its applications.
Non-woven fabric is used as artificial leather fabric, and acupuncture (or spunlace) is adopted to have the fibers tangled together, but this entanglement has its instability, (and some manufacturers add a layer of woven fabric between non-woven fabrics to increase the stability of the product). Embedded with polyurethane resin, but the fiber is relatively easy to fall off from the product, that is, it features poor wear resistance. This process can not form enough three-dimensional fibers with sparse hair on the surface so that the products feel rough and can not meet requirements for use in some areas.
In order to overcome the defects of artificial leather based on existing technology, such as no enough three-dimensional fiber, no dense hair on the surface, rough feeling and inability of meeting the use requirements in some fields, this Invention provides a manufacturing method for microfiber artificial leather, including the steps as follows:
(1) Microfiber (such as a microfiber dyed before spinning) is select as pile warp, with the filament or yarn (such as a yarn dyed before spinning) taken as ground warp and ground weft. The pile warp adopts V-shaped or W-shaped consolidation, uses the double warp-pile weaving technology to weave into double-layer pile fabric on pile weavers, and adopts pile cutters to cut the pile warp thread joining the two layers of the ground fabric so that the double-layer pile fabric could be halved into single-layer pile fabric respectively with ground warp, ground weft and V-shaped or W-shaped pile warp, featuring a three-dimensional structure;
(2) The pile fabric is immersed into polyurethane finishing liquid, padded, then treated in a coagulating liquid, washed and dried, so that the polyurethane in the pile fabric could form sponge-like continuous microporous membrane;
(3) After dried, the microporous membrane pile fabric with polyurethane contained is applied with alkali treatment, so that the pile warp could fully be dispersed into single fibers to form microfibers, and then fully washed in water to remove alkali liquid, as well as alkali-soluble monomers and oligomers;
(4) Carry out sanding, dyeing and finishing operations to obtain microfiber artificial leather.
According to the preferred technical solution of this Invention, the described microfiber shall be polyester microfiber, PTT microfiber, PA6 or PA66 microfiber, and the yarn is highly strengthened filament or other filament;
As another preferred implementation solution of this Invention, the microfiber is sea-island microfiber or split microfiber;
As another preferred implementation solution of this Invention, the multi-filament size of microfiber is 82.5-333 dtex;
As another preferred implementation solution of this Invention, the single filament size of microfiber is 0.55 dtex or below;
As another preferred implementation solution of this Invention, the multi-filament size of yarn is 82.5-222 dtex;
As another preferred implementation solution of this Invention, the polyester microfiber can adopt flame-retardant polyester microfiber, anti-static polyester microfiber, antibacterial polyester microfiber or polyester microfiber with the function of negative ions of oxygen emission;
As another preferred implementation solution of this Invention, the polyurethane resin finishing liquid described in Step (2) is a kind of solution prepared by polyurethane, DMF and anionic, and non-ionic surfactant;
As another preferred implementation solution of this Invention, the polyurethane resin in polyurethane finishing solution has its concentration of 5%-30%, and the weight ratio of anionic and nonionic surfactants is 0-5%;
As another preferred implementation solution of this Invention, the polyurethane resin has its concentration of 10%-20%, and the weight ratio of anionic and nonionic surfactants is 1-3%;
As another preferred implementation solution of this Invention, the weight ratio between the polyurethane finishing liquid and pile fabric in Step (2) is 80%-400%;
As another preferred implementation solution of this Invention, the weight ratio between the polyurethane finishing liquid and pile fabric in Step (2) is 100%-200%;
As another preferred implementation solution of this Invention, the coagulating liquid in Step (2) has the concentration of 10-30%;
As another preferred implementation solution of this Invention, the alkali treatment in Step (3) has its temperature of 95-120 degrees, with the time of 10-30 minutes;
As another preferred implementation solution of this Invention, the ground warp and ground weft in Step (1) can adopt producer-colored yarn;
As another preferred implementation solution of this Invention, the pile warp in Step (1) can adopt producer-colored microfiber;
As another preferred implementation solution of this Invention, after the pile fabric has been made, Step (1) also includes another step to coat a layer of sea-island superfine polyester non-woven fabric on the back of the hair surface;
As another preferred implementation solution of this Invention, after the microfiber artificial leather has been made, Step (4) also includes another step to coat a layer of water-soluble polyurethane.
Another technical solution of this Invention is to obtain polyester microfiber artificial leather based on the above-mentioned manufacturing methods;
The preferred solution for the invention is that artificial leather adopts yarn as ground warp and ground weft. The pile warp adopts V-shaped or W-shaped consolidation, uses the double warp-pile weaving technology to weave into double-layer pile fabric on pile weavers, and adopts pile cutters to cut the pile warp thread joining two layers of ground fabric so that the double-layer pile fabric could be halved into single-layer pile fabric respectively with ground warp, ground weft and V-shaped or W-shaped pile warp, featuring a three-dimensional structure;
Another preferred solution of this Invention is to coat a layer of sea-island superfine polyester non-woven fabric on the back of the hair surface.
Another preferred solution of this Invention is to coat a layer of water-soluble polyurethane on the back of the hair surface.
Another technical solution of this Invention is the applications of microfiber artificial leather as garment leather, shoe leather, automotive interior materials or furniture leather.
The artificial leather of this Invention features fine and smooth hair surface, high density, strong cortical feeling, good wear resistance, dimensional stability, good moisture permeability, good color fastness and excellent mechanical properties, able to be used as garment leather, shoe upper leather, car interior materials, furniture leather and so on.
Here follows the further detailed description of this Invention based on the figures and specific implementation, but such specific implementation shall not be used to limit the protection scope of this Invention.
1. Take the polyester sea-island microfiber with the microfiber filament size of 82.5-333 dtex (preferably with the microfiber filament size of 0.55 dtex or below) as pile warp (1), the highly-strengthened filament with the size of 82.5-222 dtex as ground warp (2) and ground weft (3). The pile warp (1) adopts V-shaped (as shown in FIG. 2 or FIG. 3 ) or W-shaped (as shown in FIG. 4 ) consolidation, uses the double warp-pile weaving technology to weave into double-layer pile fabric (as shown in FIG. 5 ) on pile weavers, and adopts pile cutters to cut the pile warp thread joining two layers of ground fabric so that the double-layer pile fabric could be halved into single-layer pile fabric (as shown in FIG. 6 ) respectively with ground warp (2), ground weft (3) and V-shaped or W-shaped pile warp (1) (which is called as rough surface), featuring a three-dimensional structure;
(2) Immerse the pile fabric with the finishing liquid containing 5%-30% polyurethane resin (preferably 10-20%), DMF, and 0-5% (preferably 1%-3%) anionic and non-ionic surfactant, in which weight ratio of polyurethane finishing liquid and pile fabric is 80%-400% (preferably 100%-200%). Then, the fabric shall be padded, immersed in coagulating liquid, washed in water, squeezed and dried;
Thereinto, the coagulating liquid is a kind of solution prepared by DMF with the weight ratio of 10%-30% (preferably 15%-25%) and water.
(3) Immerse the pile fabric with polyurethane contained after dried into alkaline solution, treat it under the temperature of 95-120 degrees for 10-30 minutes, dissolve the “sea” part in the sea-island polyester, fully disperse the “island” part to obtain the microfiber with the single filament size of 0.55 dtex or below, and then fully wash it in water to remove alkali, as well as alkali-soluble monomers and oligomers.
(4) Carry out sanding, dyeing and finishing, and obtain polyester microfiber artificial leather.
Thereinto, the sanding may have great impact on the plush feeling of the artificial leather hair surface, and this Invention adopts the sandpaper (220-600 meshes) surfaces of different types based on test to carry out several times of sanding treatment (first heavier, and then lighter) and obtain suedette artificial leather featuring standing hair and fine silky feeling.
Dyeing steps: Select high-quality dispersed dyes, such as those dispersed dyes featuring good wash fastness and excellent light fastness, make use of overflow dyeing machine for dyeing, strictly control the dyeing process conditions (130° C., 60 minutes), and strengthen after-dyeing wash to ensure uniform product color, pure shade and good color fastness.
(5) Coat with a layer of sea-island polyester microfiber (4) (as shown in FIG. 6 ) on the back of the hair-standing surface to further improve its wear resistance; or a layer of water-soluble polyurethane resin on the back of the hair surface to reduce the shedding of hair.
Test the artificial leather microfiber obtained in Example 1 respectively from the gram weight, thickness, TABER wear resistance, flooding fade, bending at room temperature, bursting strength, tensile strength, elongation, tear strength, friction fade, peel strength and wet-type test, with the results as follows:
| Test | Test | ||||
| Test Item | Unit | Results | Test Item | Unit | Results |
| Gram weight | g/m2 | 390 | Tensile | A-oriented | Kg/cm | 16 |
| Thickness | mm | 1.0 | strength | B-oriented | Kg/cm | 14 |
| Breadth | M | 1.4 | Elongation | A-oriented | % | 85 |
| TABER wear | Cycles | No damage after | B-oriented | % | 120 | |
| resistance | 100,000 times | |||||
| Flooding fade | AATCC | 4.0 | Tear | A-oriented | Kg | 4.7 |
| Bending at | Cycles | No crack after | strength | B-oriented | kg | 4.2 |
| room temperature | 100,000 times | |||||
| Bursting | Kg/cm2 | 20 | Friction | Dry-type | ATCC | 4.5 |
| strength | fade | |||||
| Peel strength | Kg/cm | 3.4 | Wet-type | AATCC | 4.0 | |
Above shows the detailed description of this Invention structure and its working process, but it can not be determined that the specific implementation of this Invention be limited to such description. Those general technical staff classified as the corresponding technical field of this Invention can also make a number of simple inferences or replacement on condition that the concept of this Invention has been followed, which should be regarded as within the protection of this Invention.
Claims (18)
1. A method of manufacturing a microfiber artificial leather, the method comprising:
selecting microfiber as pile warp, and yarn as ground warp and ground weft, wherein the pile warp adopts V-shaped or W-shaped consolidation, uses the double warp-pile weaving technology to weave into double-layer pile fabric on pile weavers, and uses pile cutters to cut the pile warp thread joining the two layers of ground fabric so that the double-layer pile fabric is halved into single-layer pile fabric respectively with ground warp, ground weft and V-shaped or W-shaped pile warp to form a hair surface, featuring a three-dimensional structure;
immersing the pile fabric in a polyurethane finishing liquid, padding the pile fabric, then treating the pile fabric in a coagulating liquid;
washing and drying the pile fabric so that the polyurethane in the pile fabric forms a continuous microporous membrane;
after drying, applying an alkali treatment to the microporous membrane pile fabric comprising polyurethane so that the pile warp is fully dispersed into single fibers to form microfibers, and then fully washing the microfibers in water to remove alkali liquid remaining from the alkali treatment, as well as alkali-soluble monomers and oligomers;
carrying out sanding, dyeing and finishing operations to obtain microfiber artificial leather.
2. The manufacturing method of claim 1 , wherein the microfiber is a polyester microfiber, polytrimethylene terephthalate (PTT) microfiber, polyamide 6 (PA6) or polyamide 66 (PA66) microfiber, and the yarn is a filament.
3. The manufacturing method of claim 2 , wherein the microfiber is sea-island microfiber or split microfiber.
4. The manufacturing method of claim 3 , wherein the microfiber has a multi-filament size of 82.5-333 dtex.
5. The manufacturing method of claim 4 , wherein the microfiber has a filament size of 0.55 dtex8 or below.
6. The manufacturing method of claim 2 , wherein the described yarn has a multi-filament size of 82.5-222 dtex.
7. The manufacturing method of claim 2 , wherein the polyester microfiber is selected from flame-retardant polyester microfiber, anti-static polyester microfiber, antibacterial polyester microfiber, or polyester microfiber with the function to emit negative ions of oxygen.
8. The manufacturing method of claim 1 , wherein the polyurethane resin finishing liquid is a solution comprising polyurethane resin, dimethyl formamide (DMF), and anionic and non-ionic surfactants.
9. The manufacturing method of claim 8 , wherein the polyurethane resin finishing liquid has a polyurethane resin content in a range of from 5%-30% by weight of the polyurethane resin finishing liquid, and a anionic and nonionic surfactants content in a range of from 0-5% by weight of the polyurethane resin finishing liquid.
10. The manufacturing method of claim 9 , wherein the polyurethane resin content is in a range of from 10%-20% by weight of the finishing liquid, and the anionic and nonionic surfactants content is in a range of from 1%-3% by weight of the polyurethane resin finishing liquid.
11. The manufacturing method of claim 1 , wherein a weight ratio between the polyurethane finishing liquid and pile fabric is in a range of from 0.8:1 to 4:1.
12. The manufacturing method of claim 11 , wherein the weight ratio between the polyurethane finishing liquid and pile fabric is in a range of from 1:1 to 2:1.
13. The manufacturing method of claim 1 , wherein the coagulating liquid is a dimethyl formamide (DMF) solution, where the DMF is present in an amount of from 10-30% by weight of the coagulating liquid.
14. The manufacturing method of claim 1 , wherein the alkali treatment occurs at a temperature of 95-120 degrees Celsius and for a duration of 10-30 minutes.
15. The manufacturing method of claim 1 , wherein a yarn dyed before spinning is selected as the ground warp and ground weft.
16. The manufacturing method of claim 1 , wherein a microfiber dyed before spinning is selected as the pile warp.
17. The manufacturing method of claim 1 , further comprising: after the pile fabric has been made, coating a layer of sea-island microfiber polyester non-woven fabric on the back of the hair surface.
18. The manufacturing method of claim 1 , further comprising: after the microfiber artificial leather has been made, coating a layer of water-soluble polyurethane on the back of the hair surface.
Applications Claiming Priority (7)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201020601285.1 | 2010-11-11 | ||
| CN2010206012851U CN202064216U (en) | 2010-11-11 | 2010-11-11 | Superfine fiber artificial leather |
| CN 201010539516 CN102061629B (en) | 2010-11-11 | 2010-11-11 | Superfine fiber artificial leather and manufacturing method thereof |
| CN201010539516 | 2010-11-11 | ||
| CN201020601285U | 2010-11-11 | ||
| CN201010539516.5 | 2010-11-11 | ||
| PCT/CN2011/000055 WO2012062020A1 (en) | 2010-11-11 | 2011-01-13 | Superfine fiber artificial leather and preparation method thereof |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| US20130000772A1 US20130000772A1 (en) | 2013-01-03 |
| US9085835B2 true US9085835B2 (en) | 2015-07-21 |
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US13/203,665 Active 2033-01-04 US9085835B2 (en) | 2010-11-11 | 2011-01-13 | Kind of microfiber artificial leather and its manufacturing methods |
Country Status (8)
| Country | Link |
|---|---|
| US (1) | US9085835B2 (en) |
| EP (1) | EP2472003A4 (en) |
| JP (1) | JP2012533695A (en) |
| KR (1) | KR101307335B1 (en) |
| BR (1) | BR112012015550A2 (en) |
| RU (1) | RU2527367C1 (en) |
| TW (1) | TW201204890A (en) |
| WO (1) | WO2012062020A1 (en) |
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| US20150257524A1 (en) * | 2012-10-04 | 2015-09-17 | Kenji Nakamura | Bristle for antibacterial cosmetic brush, and antibacterial cosmetic brush obtained using said bristle and process for producing same |
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| US20150240389A1 (en) * | 2014-02-25 | 2015-08-27 | Yi-yung Chen | Dope-Dyed Core-Sheath Type Composite Fiber |
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| KR101676939B1 (en) * | 2015-01-07 | 2016-11-16 | 남택욱 | Manufacture of synthetic suede method and thereby made synthetic suede |
| BE1024400B1 (en) * | 2016-07-15 | 2018-02-13 | Michel Van De Wiele Nv | Device for cutting pile threads on a weaving machine |
| ES2837394T3 (en) | 2017-02-28 | 2021-06-30 | Toray Industries | Sheet-like material |
| KR102635537B1 (en) * | 2019-06-11 | 2024-02-07 | (주)엘엑스하우시스 | Artificial leather for vehicle interior material and method for manufacturing the same |
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| KR102635538B1 (en) * | 2019-06-11 | 2024-02-07 | (주)엘엑스하우시스 | Artificial leather for vehicle interior material and method for manufacturing the same |
| CN113403728B (en) * | 2021-06-24 | 2023-05-02 | 沂水恒泰纺园有限公司 | Manufacturing method of polyester rolling brush velvet with high rebound velvet surface performance |
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| US20240173950A1 (en) * | 2022-11-30 | 2024-05-30 | Lear Corporation | 100% polyester mono-material providing suede-like a-surface with 100% recyclability at end of life |
| WO2025132945A1 (en) | 2023-12-20 | 2025-06-26 | Infineum International Limited | Lubricant compositions containing aralkyl substituted diphenylamine antioxidant |
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| US11266344B2 (en) | 2016-09-21 | 2022-03-08 | Samsung Electronics Co., Ltd. | Method for measuring skin condition and electronic device therefor |
Also Published As
| Publication number | Publication date |
|---|---|
| WO2012062020A1 (en) | 2012-05-18 |
| KR101307335B1 (en) | 2013-09-10 |
| EP2472003A1 (en) | 2012-07-04 |
| JP2012533695A (en) | 2012-12-27 |
| EP2472003A4 (en) | 2013-09-18 |
| KR20120063459A (en) | 2012-06-15 |
| BR112012015550A2 (en) | 2016-05-03 |
| TW201204890A (en) | 2012-02-01 |
| RU2527367C1 (en) | 2014-08-27 |
| US20130000772A1 (en) | 2013-01-03 |
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